WOLKITE UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF TEXTILE ENGINEERING
TITLE: ENHANCING PRODUCTIVITY OF KNITTING BY
REDUCING IDLE TIME OF THE MACHINES.
PREPARED BY:
NAME ID NO
1. ABDUREZAK TEMAM 0036/12
2. KIDUS AMANUEL 0864/12
3. SULEMAN GIRMA 1358/12

ACADE
MIC ADVISOR: -Mr. Fekade

WOLKITE, ETHIOPIA
Apr, 2024
 ACKNOWLEDGMENT
We perceive as this opportunity as a big milestone in our career development. We will strive to
use gained skills and knowledge in the best possible way, and we will continue to work on your
improvement, in order to attain desired career objectives. We appreciate very much the
knowledge you shared with us, the time you spent on proofreading our papers and our work
together. Hope to continue cooperation with you in the future. Finally, we must express our very
profound gratitude to our parents for their love, understanding, encouragement, confidence and
providing us with unfailing support and Continuous encouragement throughout our years of
study and through the process of researching and writing this final year project.

Table of Contents
Type chapter title (level 1) 1
 Type chapter title (level 2) 2
Type chapter title (level 3) 3
Type chapter title (level 1) 4
Type chapter title (level 2) 5
Type chapter title (level 3) 6

CHAPTER ONE
INTRODUCTION
Knitting is a method for production of textile fabrics by interlacing yarn loops with loops of the
same or other yarns. It is used to create many types of garments. Knitting may be done by
hand or by machine.

Knitting creates stitches: loops of yarn in a row, either flat or in the round (tubular). There are
usually many active stitches on the knitting needle at one time. Knitted fabric consists of a
number of consecutive rows of connected loops that intermesh with the next and previous rows.
As each row is formed, each newly created loop is pulled through one or more loops from the
prior row and placed on the gaining needle so that the loops from the prior row can be pulled off
the other needle without unraveling.

There are 2 things making the knit fabric, they are course and Wales.

Wales is the vertical yarn; wales lines are fixed by the machine gauge. This cannot be changed.
Course is the horizontal yarn; coarse lines can be altered by adjusting in the machine. This is
called Texture.

Classification of knitted fabrics

The knitting industry is divided into two distinct
 Weft Knitting
 Warp knitting

Weft knitting is a method of knitting where a single yarn is used to create loops horizontally
across the fabric. It is a popular technique used in the production of various knitted fabrics,
including sweaters, scarves, socks, and other garments. In weft knitting, the yarn is fed into a
knitting machine or worked by hand using knitting needles. The yarn is formed into loops that
interlock with each other to create a fabric. The loops can be created in different ways, such as
by hand manipulation, using a knitting machine with latch needles, or using a circular knitting
machine.

Warp knitting refers to a specific type of knitting where the yarns run vertically or lengthwise
along the fabric. In warp knitting, the yarns are arranged in parallel and are fed into the knitting
machine as warp threads. The fabric is formed by the vertical movement of the needles, which
create loops that interlock with the previous rows of loops. This interlocking structure gives
warp-knitted fabrics stability and prevents them from unraveling. Warp knitting machines can be
categorized into two main types: raschel and tricot machines. Raschel machines have latch
needles that can be individually controlled, allowing for more complex stitch patterns and
designs. Tricot machines, on the other hand, have compound needles that can create a wide range
of stitch structures.

Circular Knitting machine

also known as a circular knitting loom or circular knitting frame, is a type of knitting machine
used to create seamless tubular or circular knitted fabrics. It is commonly used in the textile
industry for producing items such as socks, hats, sweaters, and other types of garments.

Diagram of Circular Knitting Machine:

 Machine parts of circular knitting machine
1. Legs
2. Cylinder
3. Dial
4. Needle
5. Cam Parts
6. Feeder guide
7. Cam
8. Supply Package
9. Creel
10. Top Stop motion
11. Anti snarl device
12. Tensioner
13. Positive feeder
14. Knitted fabric
15. Fabric spreader
16. Fabric withdrawal roller
17. Fabric winding roller

There are mainly two types of knitting machine i.e. circular knitting machine and flatbed
knitting machine. circular knitting machine is one of them. some parts of circular knitting
machine are given below:

 Creel: creel is called the holder of cone. cone is placed in a creel for feeding the
yarn to the feeder.
  Yarn Feeder: yarn is feed through the feeder, number of feeder is depends on the
design of the fabric

 VDQ pulley: G.S.M of the knit fabric is collected by VDQ pulley, pulley is used
for controlling the stitch length of the fabric.

 Guide: Guide is called the supporting element. Guide is use to guide the yarn.

 Tensioners: Tensioner is used to apply and maintain desired tension to the yarn.
Desired yarn tension is essential for smooth flow of yarn from the package to the needle
for loop formation.
 Needle detector: This part detects the any type of faults of needles.

 Cylinder: cylinder is the main parts of a knitting machine. Adjustment of a cylinder is

important. Cylinder carries needle, sinker, cam and many more.

 Spreader: a flat wooden/metal body placed inside the fabric tube. It floats inside the
fabric tube above the take-down rollers i.e., in the zone where the tubular fabric is
converted to flattened or two-fold state.
  Inlet and Outlet Stop Motion: It is an important part of the machine. It stops the
machine instantly when a yarn breaks.

Process flow chart of circular knitting machine:

Some circular knitting machine description

  Single Jersey Machines: Single Jersey machines are equipped with a single “cylinder”,
about 30-inch diameter, of needles that produce plain fabrics.

 Double jersey machines: It is a single jersey machines with a “dial” which houses an
extra set of needles positioned horizontally adjacent to the vertical cylinder needles. This
extra set of needles allows the production of fabrics that are twice as thick as single jersey
fabrics.

 Rib circular knitting machine: There is one set of needles on the circumference of the
vertical cylinder and another set of needles on a horizontal dial. Two sets of needles
remain at the right angle with each other.

Type of knit Fabric:

1. Jersey
2. Rib Knit
3. Interlock
4. French Terry
5. Ponte Knit
6. Sweater Knit
7. Jacquard Knit

3.7 Basic Knitting Element

There are 3 Basic Knitting elements. They are:

1. Needle - Needle is raised to clear the old loop from the hook & to receive the
new loop above it on the needle stem.

2. Sinker - It is most important element of the machine. Its help to loop forming, knocking over and
holding down the loop.
3. Cam - Cams are the device that convert the rotary drive into a suitable reciprocating action for
the needles or other elements.

1.2. STATEMENT OF THE PROBLEM

The productivity of knitting operations heavily depends on the efficient utilization of knitting
machines. However, one significant challenge in the knitting industry is the occurrence of idle
time in machines, which hampers overall productivity. Idle time refers to the duration when
knitting machines remain inactive or are not fully utilized for production, resulting in decreased
output and efficiency. Reducing the idle time of knitting machines is crucial for enhancing
productivity and maximizing output. By addressing the causes of idle time, manufacturers can
aim to optimize machine utilization and minimize unproductive periods. The knitting industry
faces a significant challenge in achieving optimal productivity because of this downtime in
knitting machines. This problem hampers the overall productivity of knitting operations and can
have detrimental effects on profitability, customer satisfaction, and competitiveness in the
market.

RESEARCH QUESTIONS

1. What are the main factors contributing to the idle time of knitting machines and reducing
their productivity?
2. How much idle time and production loss do the knitting machines typically experience?
3. What are the current strategies and techniques employed to reduce idle time in knitting
machines?
1.3. OBJECTIVE
1.3.1. General Objective
 Enhance the productivity of knitting operations by effectively reducing the idle time of
machines.

1.3.2. Specific Objective

 Identify the main factors contributing to idle time in knitting machines.
 Determine strategies and techniques to reduce idle time and enhance production.
 To analyze the total idle time, time efficiency and production loss.

1.4. SCOPE OF THE PROJECT

The project will specifically concentrate on identifying and addressing idle time in knitting
machines to improve overall productivity. The primary objective is to reduce unproductive
periods and optimize machine utilization. The project will involve studying and collecting data
from a representative sample of knitting manufacturing facilities by gathering data on idle time,
production output, machine utilization, and other relevant metrics. It will evaluate existing
strategies and interventions employed to reduce idle time in knitting machines. This may involve
studying the effectiveness of different approaches.

1.5. SIGNIFICANCE OF THE STUDY

Improved Production Efficiency: By reducing idle time in knitting machines, the study aims to
enhance production efficiency. This can lead to increased output without the need for additional
resources, resulting in higher productivity levels for knitting manufacturers.

Cost Savings: Idle time in knitting machines represents a waste of resources and can incur
unnecessary costs. By reducing idle time, the study can help knitting manufacturers minimize
operational expenses associated with unproductive periods, such as energy consumption and
labor costs.

Enhanced Competitiveness: Improving productivity through idle time reduction can help
knitting manufacturers gain a competitive edge in the market. Efficient utilization of machines
can lead to faster turnaround times, better delivery performance, and improved customer
satisfaction, positioning the manufacturers as reliable and efficient partners for clients.
Resource Optimization: Minimizing idle time of machines allows for better resource allocation
and utilization. By maximizing the use of knitting machines, manufacturers can make the most of
their existing equipment, reducing the need for additional investments and optimizing their
overall resource management.

Process Optimization: The study will identify and address factors contributing to idle time, such
as yarn changeovers, machine setup, and material availability. By analyzing and optimizing these
processes, manufacturers can streamline their operations, reduce downtime, and improve overall
process efficiency.
 CHAPTER TWO
LITERATURE REVIEW

INTRODUCTION
In the book of D. J. Spencer, “Knitting Technology”, third edition, Wood head Publishing Ltd.,
April 2001 he wrote A knitting machine contains different types of machine parts such as
needles, cams, sinkers, Fabric take-down mechanism, creel, a yarn metering and storage device,
yarn breakage indicator, feeders and lubricator. All those machine parts are responsible to
increase or decrease the productivity of knit fabric production. Due to the problem of machine
parts, machine has to shut down for certain period. For this it reduced productivity overall loss of
efficiency of the machine.

Yarn-needle and yarn-yarn friction values, machine tightness factor, and machine speed are
factors that affect knitting machine stops S. Döonmez et al 2004. Defects like yarn breakage,
maintenance, needle breakage, and technical problems cause knitting machine idleness, resulting
in time and efficiency losses E. Khalil et al 2014.

In the book of Iyer, Mammel, Schach “Circular Knitting”, second edition, 1995. The demand
for knit garment products all over the world are rapidly growing because of more interest in
knitted fabrics due to its simple production technique, low cost, high levels of clothing comfort
and wide product range. Knitting technology meets the rapidly-changing demands of fashion and
usage. Knitted fabrics not only possess stretch and provide freedom of movement, but they also
have good handle and easily transmit vapor from the body.

In the book of Iyer, Mammel, Schach “Circular Knitting”, second edition, 1995. Knitted fabric
can be classified into two categories, namely weft knitted fabric and warp knitted fabric. In weft
knitting a yarn presented horizontally is kinked into a row of loops. To achieve these needles can
be moved simultaneously and the loops formed one after the other or at the same time or the
needles are moved successively to form the loops.
In a journal of Md.Solaiman, Elias Khalil ;Mostafizur Rahman; Joy Sarkar they identify the
causes from single, Rib Machine randomly and calculate production randomly and find the basic
causes of efficiency loss.
Factors for knitting machine idleness

Factors of knitting machine idleness are: Yarn breakage, cleaning of the machine Lubrication,

Operator carelessness. Reza MH, Hossain MK 2015. The main reason for knitting machine
idleness is the condition of the working environment, which can cause yarn breakage and affect
fabric quality Md. Anisuzzaman Rassel et al.2019

Production and efficiency

According to Spencer DJ. Knitting technology 2001 May 11 there are basically three factors,
which are responsible for optimum fabric production. They are:
1, Yarn Characteristics: Yarn quality plays a significant role in knitting machine performance.
Factors such as tenacity, breaking extension, elasticity, and friction of yarn influence how
smoothly the machine operates. Poor yarn quality can lead to issues like yarn breakages during
knitting, affecting overall productivity.

2, Machine Quality Requirements: Machine cleaning and fabric roll cutting are common causes of
stoppages. Machine cleaning, in particular, occupies a significant portion of stoppage time. Needle
breakages can occur due to worn-out or damaged needles, impacting both production and fabric
quality.

3, Knitting production conditions: The environment in which knitting occurs affects productivity.
Factors include temperature, humidity, and lighting. Set-offs (misalignment of needles) can
occur due to improper settings or environmental conditions, yarn joining during knitting can lead
to stoppages if not executed seamlessly, oil problems (such as insufficient lubrication) affect
machine performance and may cause stoppages.

Yarn breakage is not only responsible for production losses, but it also creates quality problems
on fabric texture. M. M. Hoque Jul 30, 2019. Using yarn input tension (Ti) as a means of process
control in circular knitting machines can prevent or quickly detect defects, reducing machine
idleness and productivity losses. M. Araújo, A. Catarino, Hu Hong Oct 31, 1999.

Efficiency is used with the specific purpose of relaying the capability of a specific application of
effort to produce a specific outcome effectively with a minimum amount or quantity of waste,
expense, or unnecessary effort. Y. Kovalyov et al 2021. If outcome is greater than the input
materials in this case machine is considered highly efficient. The efficiency of a machine
depends on many factors such as machine speed, input materials quality, Routine maintenance,
skilled machine’s operator, auto spacing and oiling, power failure etc.

Gaps in the literature: While much research may focus on technological solutions, there
may be limited exploration of the role of human factors in reducing machine idle time.
Investigating the impact of operator training, scheduling practices on productivity could be
valuable. Much of the existing literature may focus on general productivity improvements in
knitting operations without considering the specific types of knitting machines. Different types
of machines (e.g., circular knitting machines, flat knitting machines) may have unique idle time
issues and potential solutions that warrant further investigation. Further research could be
conducted to identify the specific causes and patterns of idle time in knitting machines. This
could involve detailed analysis of production data, observation studies, and interviews with
machine operators and technicians to understand the root causes of idle time and the factors
contributing to its occurrence.
 CHAPTER THREE
MATERIALS AND METHODS
3.1. MATERIALS
Material:
Article type Yarn count Machine Gauge GSM

Single jersey 30 24 or 28 131 or 132

Rib 30 18 166

Table 1.1 Material used

Equipment: Single jersey knitting machine, Stopwatch, Calculator and pen are used

2.7.2 Methods of data collection

For the completion of the project, primary and secondary data sources were applied or
used.
Primary sources:
 Observation: has been done in this method of data collection, we collected data
which are useful for the project by observing working condition of machines 
Interviews: in this method of data collection involves oral communication with workers
or employees. we asked questions to whom it concerned to production manager.
Secondary source:
 Company profile: we used the daily reports, production records and progress boards
of the company.

Problem Title Data Data

Identification Selection Collection Presentation

Conclusion and Result And Data

Recommendation Discussion Analysis
2.8 Data Presentation

Data is organized or presented in the form of tables and written form. We have presented
different data collected from various sources in tabular form.

Table 1.2 Total production in different machines in (kg/shift) on Day 1 per shift.

Machin particl coun GS Gaug Actual production (kg/hr.)

e e t M e 1st 2nd roll 3rd 4th Total
number roll roll roll
8 Jersey 30 131 28 22.85k 25.20k 20.35k 21.80k 90.2kg
g g g g
9 Jersey 30 132 28 20.15k 26.95k 17.75k 25.65k 90.5kg
g g g g
12 Jersey 30 131 24 19.55k 19.85k 16.50k 19.85k 75.75k
g g g g g
13 Jersey 30 131 24 24.05k 27.35k 22.95k 20.65k 95kg
g g g g

Total = 351.45kg is the total production in (kg/shift)

Machine number 12 stopped for 9 minutes because of mechanical maintenance
Machine number 9 stopped for 40 minutes because the yarn needed to be changed
All the machines stopped for 45 minutes because of no electric power
and then 20 minutes for cleaning the room.
Total time loss for those causes:114 minutes.
Table 1.3 Total production in different machines in (kg/shift) on Day 2 per shift.

Machin particl coun GS Gaug Actual production (kg/hr.)

e e t M e 1st roll 2nd roll 3rd roll 4th roll Total
number
8 Jersey 30 131 28 25.45k 22.20k 21.30k 21.55k 90.5kg
g g g g
 9 Jersey 30 132 28 25.25k 22.85k 20.8kg 19.75k 88.65k
g g g g
12 Jersey 30 131 24 21kg 14.15k 21.3kg 18.75k 75.19k
g g g
13 Jersey 30 131 24 26.85k 24.20k 21.55k 25.15k 97.75k
g g g g g
Total = 352.09kg is the total production in (kg/shift)
Machine number 12 stopped for 1:30 hour because mechanical maintenance
All the machines stopped for 20 minutes because of cleaning the room.
Total time loss for those causes:110 minutes.
Table 1.4 Total production in different machines in (kg/shift) on Date 3 per shift.

Machin particle count GSM Gauge Actual production (kg/hr.)

e 1st 2nd roll 3rd 4th Total
number roll roll roll
5 Rib 30 166 18 13.85kg 15.65kg 18.80kg - 48.3kg
8 Jersey 30 131 28 22.10kg 20.95kg 17.10kg 19.20k 79.35kg
g
9 Jersey 30 132 28 25.45kg 25.80kg 22.10kg 25.20k 98.55kg
g
12 Jersey 30 131 24 22.65kg 23.90kg - - 46.55kg
13 Jersey 30 131 24 21.40kg 16.45kg 17.35kg 19.15k 74.35kg
g
Total = 347.1kg is the total production in (kg/shift)
Machine number 5 stopped for 2 hours because mechanical maintenance
Machine number 12 stopped for 4:40 hour because of electric problem
All the machines stopped for 20 minutes because of cleaning the room
And 35 minutes because of no electric power source.
Total time loss for those causes: 455 minutes.
Table 1.5 Total production in different machines in (kg/shift) on Day 4 per shift.
 Machin particle count GSM Gauge Actual production (kg/hr.)
e 1st 2nd roll 3rd 4th Total
number roll roll roll
5 Rib 30 166 18 14.45kg 15.90kg 17.25kg 15.60k 63.2kg
g
8 Jersey 30 131 28 23.60kg 21.10kg 20.55kg 18.05k 83.3kg
g
9 Jersey 30 132 28 22.65kg 21.35kg 24.35kg 26.95k 95.3kg
g
12 Jersey 30 131 24 18.10kg 19.05kg 16.35kg 18.25k 71.75kg
g
13 Jersey 30 131 24 15.65kg 22.55kg 16.95kg 19.65k 74.8kg
g
Total = 388.35 kg is the total production in (kg/shift).
Machine number 12 stopped for 40 minutes because the yarn was changing.
All the machines stopped for 20 minutes because of cleaning the room.
And 30 minutes because workers were training and practicing.
Total time loss for those causes: 90 minutes.
Table 1.6 Total production in different machines in (kg/shift) on Day 5 per shift.

Machine particl count GSM Gauge Actual production (kg/hr.)

number e 1st 2nd roll 3rd 4th Total
roll roll roll
5 Rib 30 166 18 17.30kg 14kg 12.80kg 9.60kg 53.7kg

8 Jersey 30 132 28 22.85kg 26.30kg 17.10kg 29.65kg 95.9kg

9 Jersey 30 131 24 25.45kg 32.45kg 29.45kg 25kg 112.35kg

12 Jersey 30 131 24 21.95kg 23.90kg 21.30kg 20.80kg 87.95kg

Total = 347.1kg is the total production in (kg/shift)

Machine number 5 stopped for 2 hours because of breakage of yarn
Machine number 8 stopped for 1 hour because of changing the yarn
All the machines stopped for 30 minutes because of cleaning the room
Total time loss for those causes: 210 minutes.
2.9 Data Analysis

As it can be seen from the above the different tables the actual production varies on each
day from 1 to day 5 in shift 1, so that we can calculate the total actual production, average
actual production.

Calculated production time required: 8x60=480 min

On the basis of Table no :1.9
Total time loss for those causes: 114 minutes
Actual production time: (480-114) min = 366 minutes

Time Efficiency = actual time / calculated time * 100

= 366 / 480 * 100

= 76.25%

Calculated production time required: 8x60=480 min

On the basis of Table no :1.10
Total time loss for those causes: 110 minutes
Actual production time: (480-110) min = 370 minutes

Time Efficiency = actual time / calculated time * 100

= 370 / 480 * 100

= 77.08%

Calculated production time required: 8x60=480 min

On the basis of Table no :1.11
Total time loss for those causes: 455 minutes
Actual production time: (480-455) min = 25 minutes

Time Efficiency = actual time / calculated time * 100

 = 25 / 480 * 100

= 5.2%

Calculated production time required: 8x60=480 min

On the basis of Table no :1.12
Total time loss for those causes: 90minutes
Actual production time: (480-90) min = 390minutes

Time Efficiency = actual time / calculated time * 100

= 390 / 480 * 100 = 81.25%

Calculated production time required: 8x60=480 min

On the basis of Table no :1.13
Total time loss for those causes: 210 minutes
Actual production time: (480-210) min = 270 minutes

Time Efficiency = actual time / calculated time * 100

= 270/ 480 * 100

= 56.25%

Total actual production of 5 days per shift:

= 351.45kg + 352.09kg + 347.1kg + 388.35 kg+ 347.1kg
= 1786.09kg
Average actual production = Total actual production/5
=1786.09kg/5
=357.218kg
Production loss, production loss in (percent, month, year) can also be calculated
using the table below.
Table 1.7 Daily production per shift on Date 06/07/23

Article Count GSM Gauge Production

(kg/shift)
Jersey 30 132 28 182.25
 Rib 30 166 18 35.55
Jersey 24 132 28 145.35

Planned production in yirgalem addis factory is 250 kg/shift as the company advisor
shown as from a data table, so that we can insert it in the formula to find Production loss.
Let’s us take the first jersey to calculate production loss:
Production loss for the first jersey = Planned production – Actual production
= 250 – 182.25
= 67.75kg/shift
Production loss in a day = Production loss * 2
= 67.75 * 2
= 135.5 kg/day
Production loss in a month = Production loss per day * 26 days
= 135.5 kg/day * 2= 3523 kg/month
Production loss in a year = Production loss per month * 12 months
= 3523kg/month * 12months
= 42276kg/year

Let’s us take the second rib to calculate its production loss:

Production loss for the second rib = Planned production – Actual production
= 250 – 35.5
= 214.5kg/shift
Production loss in a day = Production loss * 2
= 214.5 * 2
= 429 kg/day
Production loss in a month = Production loss per day * 26 days
= 429 kg/day * 26
= 11154 kg/month
Production loss in a year = Production loss per month * 12 months
= 11154 kg/month * 12months
= 133848 kg/year
2.10 Cost analysis

Price of one kg knitted fabric = 80birr

Production loss in a day for single jersey = 135.5kg/day * 80birr

= 10,840birr/day
Production loss in a month for single jersey = 10,840 birr/day * 26
= 281,840 birr/month
Production loss in a year for single jersey = 281,840 birr/month * 12
= 3,382,080 birr/year

CHAPTER FOUR
4. RESULT AND DISCUSSION